Generating optimized tool paths and machine commands for beam cutting tools

Abstract

A facility for automated modelling of the cutting process for a particular material to be cut by a beam cutting tool, such as a waterjet cutting system, from empirical data to predict aspects of the waterjet's effect on the workpiece across a range of material thicknesses, across a range of cutting geometries, and across a range of cutting quality levels, all of which may be broader than, and independent of the actual requirements for a target workpiece, is described.

We claim: 
     
       1. A method in a computing system for using a cutting model having outputs to compile a tool path for a waterjet cutting project for a waterjet cutting tool expected to have a particular operating condition at the beginning of the waterjet cutting project, the method comprising:
 determining a point in the waterjet cutting project by which the initial operating condition of the waterjet cutting tool will have changed to a subsequent operation condition different from the initial operating condition; 
 determining a correction transformation for the cutting model based, at least in part, on both the initial and subsequent operating conditions; 
 for a portion of the waterjet cutting project before the determined point, using outputs of the cutting model without alteration to compile the tool path; 
 for a portion of the waterjet cutting project after the determined point:
 applying the correction transformation for the cutting model to the outputs of the cutting model to obtain corrected cutting model outputs; and 
 using the corrected cutting model outputs to compile the tool path. 
 
 
     
     
       2. The method of  claim 1 , wherein the particular operating condition includes at least one of an abrasive flow rate, catcher tank water temperature, or workpiece position. 
     
     
       3. The method of  claim 1 , wherein the correction transformation for the cutting model includes adjustment in at least one of a speed, taper, angle, or kerf width. 
     
     
       4. The method of  claim 1 , wherein the method is performed before the beginning of the waterjet cutting project. 
     
     
       5. The method of  claim 1 , wherein at least a part of the method is performed after the beginning of the waterjet cutting project. 
     
     
       6. The method of  claim 1 , wherein the determining the point in the waterjet cutting project and the determining the correction transformation for the cutting model is performed at a time based on acceleration and/or deceleration characteristics of a cutting head of the waterjet cutting tool such that the determining the point in the waterjet cutting project and the determining the correction transformation for the cutting model is completed in time to allow for acceleration and/or deceleration of the cutting head of the waterjet cutting tool prior to the determined point. 
     
     
       7. A computer-readable storage medium storing instructions that, when executed by a computing system, cause the computing system to perform a process for using a cutting model having outputs to compile a tool path for a waterjet cutting project for a waterjet cutting tool expected to have a particular operating condition at the beginning of the waterjet cutting project, the process comprising:
 determining a point in the waterjet cutting project by which the initial operating condition of the waterjet cutting tool will have changed to a subsequent operation condition different from the initial operating condition; 
 determining a correction transformation for the cutting model based, at least in part, on the initial and subsequent operating conditions; 
 for a portion of the waterjet cutting project before the determined point, using outputs of the cutting model without alteration to compile the tool path; 
 for a portion of the waterjet cutting project after the determined point:
 applying the correction transformation for the cutting model to the outputs of the cutting model to obtain corrected cutting model outputs; and 
 using the corrected cutting model outputs to compile the tool path. 
 
 
     
     
       8. The computer-readable storage medium of  claim 7 , wherein the correction transformation for the cutting model includes adjustment in at least one of a speed, taper, angle, or kerf width. 
     
     
       9. The computer-readable storage medium of  claim 7 , wherein the determining steps of the process are performed before the beginning of the waterjet cutting project. 
     
     
       10. The computer-readable storage medium of  claim 7 , wherein at least one of the determining steps of the process are performed after the beginning of the waterjet cutting project. 
     
     
       11. The computer-readable storage medium of  claim 7 , wherein the process further comprises determining, during the waterjet cutting project, intra-project cutting test results and, in response to the intra-project cutting test results, increasing the pressure of a cutting beam or providing an indication to replace a mixing tube. 
     
     
       12. The computer-readable storage medium of  claim 7 , wherein the determining the point in the waterjet cutting project and the determining the correction transformation for the cutting model is performed at a time based on acceleration and/or deceleration characteristics of a cutting head of the waterjet cutting tool such that the determining the point in the waterjet cutting project and the determining the correction transformation for the cutting model is completed in time to allow for acceleration and/or deceleration of the cutting head of the waterjet cutting tool prior to the determined point. 
     
     
       13. The computer-readable storage medium of  claim 7 , wherein the particular operating condition includes at least one of an abrasive flow rate, catcher tank water temperature, or workpiece position. 
     
     
       14. A computing system for using a cutting model having outputs to compile a tool path for a cutting project for a cutting tool expected to have a particular operating condition at the beginning of the cutting project, the computing system comprising:
 one or more processors; and 
 one or more memories storing instructions that, when executed by the one or more processors, cause the computing system to perform a process comprising:
 determining a point in the cutting project by which the initial operating condition of the cutting tool will have changed to a subsequent operation condition different from the initial operating condition; 
 determining a correction transformation for the cutting model based, at least in part, on the initial and subsequent operating conditions; 
 for a portion of the cutting project before the determined point, using outputs of the cutting model without alteration to compile the tool path; 
 for a portion of the cutting project after the determined point:
 applying the correction transformation for the cutting model to the outputs of the cutting model to obtain corrected cutting model outputs; and 
 using the corrected cutting model outputs to compile the tool path. 
 
 
 
     
     
       15. The computing system of  claim 14 , wherein the correction transformation for the cutting model includes adjustment in at least one of a speed, taper, angle, or kerf width. 
     
     
       16. The computing system of  claim 14 , wherein the determining steps of the process are performed before the beginning of the cutting project. 
     
     
       17. The computing system of  claim 14 , wherein at least one of the determining steps of the process are performed after the beginning of the cutting project. 
     
     
       18. The computing system of  claim 14 , wherein the process further comprises determining, during the cutting project, intra-project cutting test results and, in response to the intra-project cutting test results, increasing the pressure of a cutting beam. 
     
     
       19. The computing system of  claim 14 , wherein the determining the point in the cutting project and the determining the correction transformation for the cutting model is performed at a time based on acceleration and/or deceleration characteristics of a cutting head of the cutting tool such that the determining the point in the cutting project and the determining the correction transformation for the cutting model is completed in time to allow for acceleration and/or deceleration of the cutting head of the cutting tool prior to the determined point. 
     
     
       20. The computing system of  claim 14 , wherein the particular operating condition includes at least one of an abrasive flow rate, catcher tank water temperature, or workpiece position. 
     
     
       21. The computing system of  claim 14 , wherein the cutting model:
 receives project parameter inputs including one or more of material, pressure, flow rate, abrasive type, abrasive size, or any combination thereof; and 
 produces cutting path results defining the tool path of the cutting tool. 
 
     
     
       22. The computing system of  claim 21 , wherein the cutting path results define one or more of separation speed, jet lag, kerf width, taper error, surface finish, geometry, position of a cutting front, or any combination thereof. 
     
     
       23. The computing system of  claim 21 , wherein the correction transformation for the cutting model is a modification to cutting model output that adjusts for the change in operating conditions.